Page 1 of 15 Transmission, Model S5-42 ZF Model S5-42 ZF Disassembly NOTE: For 4x4 and F-Super Duty vehicles, skip to Step 5. 1. Attach the transmission to the Bench Mounted Holding Fixture T57L-500-B or equivalent. Place the transmission in a vertical position with the front case pointing downward.

Page 2 of 15 2. Using a chisel, bend back the locking shoulder of the output flange retaining locknut (4x2 models only). 3. Attach Companion Flange Holding Tool T78P-4851-A or equivalent to the transmission output flange. 4. Loosen the hex nut that holds the output flange to the mainshaft with Thin-Walled Socket T87T-7025-AH or equivalent. Remove the flange holding tool after loosening the nut. CAUTION: Do not remove the hex nut or output flange at this time. 5. Remove 15 of the 17 8mm hex head screws that hold the front and rear cases together. Leave two screws at opposite sides of the case installed. 6. Remove any power take-off equipment installed on the transmission. 7. Remove the eight 8mm hex bolts that attach the shift tower assembly to the front case. Remove the complete gearshift lever and tower as an assembly. Rotate transmission on holding fixture so that the front case is pointing upward. 8. Remove the interlock plate and compression spring which serves as a reverse gear interlock.

Page 3 of 15 CAUTION: Make sure that parts do not inadvertently fall into transmission. 9. Place a drift punch against the detent bolt sealing cap. Hold the drift at an angle. Position the point of the drift punch so it is off-center on the cap. Drive the cap inward until spring pressure against its underside forces the cap out of its hole. Repeat this procedure for the other two detent bolt sealing caps in the front case. WARNING: CAP IS UNDER SPRING PRESSURE. ALWAYS WEAR PROTECTIVE EYEGLASSES WHEN PERFORMING THIS PROCEDURE TO ENSURE THAT CAP DOES NOT STRIKE EYES WHEN IT IS FORCED OUT BY SPRING PRESSURE. NOTE: Discard removed caps and replace with new sealing caps. 10. Remove the springs that are now protruding from the sealing cap holes. 11. Drive out the sealing caps for the two reverse idler shaft cap screws. Remove the reverse idler shaft cap screws. 12. If required, remove the back-up lamp switch, located above and slightly forward of the transmission nameplate. Remove the back-up lamp switch sealing ring.

Page 4 of 15 13. Use a suitable punch to remove the two dowel pins located in opposite corners of the rear case to front case mating surfaces. Drive them out toward the rear of the transmission. 14. Remove the two remaining hex bolts from the rear case. NOTE: The transmission input shaft is facing upward during this operation. 15. Carefully lift the front case off of the rear case. It may be necessary to push the central shift rail inwards to prevent it from "hanging up" on the front case as it is being removed. Use care to ensure that the central shift rail is not lifted off together with the front case. Refer to Transmission Front Case in this section for front case disassembly and assembly procedures. CAUTION: The mating surfaces of the two housing assemblies are coated with an adhesive sealing agent. If it is difficult to separate the two housings because of this adhesive, carefully tap the front of the front case with a soft hammer until the bond is loosened. Never use a prying device, such as a screwdriver or chisel, to force the housings apart. It could damage the surface and cause leaks. 16. Remove the central shift rail and shift finger assembly. 17. Lift the shaft out of the reverse idler gear, and remove the gear and two caged roller bearings from the rear case.

Page 5 of 15 18. Remove the three capscrews that retain the shift interlock to the rear case. 19. With the transmission in a vertical position, use Nylon Lifting Sling D87L-1000-A or equivalent to strap Gear Pack Holding Fixture T87T-7025-HH or equivalent to the mainshaft and output shaft assemblies. Pass the sling over the shift rails. 20. Place the Shift Rod Support T87T-7025-JH or equivalent over the ends of the shift rails. 21. Carefully rotate the transmission, together with the gear pack holding fixture, into a horizontal position with the holding fixture beneath the gear pack.

Page 6 of 15 22. Remove the output shaft flange retaining nut from the output shaft. Remove the flange from the output shaft. If the flange is difficult to remove, tap it loose with a hammer. 23. Carefully pull the gearpack and shift rails and their holding fixtures forward to dislodge them from the rear case. Place this assembly on a workbench. 24. If equipped, remove the bushing from the mainshaft. 25. Remove the sling from around the shift rails, gearpack, and holding fixture. 26. Turn the gearshift rails approximately 45 degrees to release them from the shift hubs. Lift the gearshift rails, forks and interlock, together with Support Tool T87T-7025-JH, off the mainshaft. 27. Using the shift rod support tool as a base, set the shift rail assembly on a workbench with the shift rails in a vertical position. Remove the interlock.

Page 7 of 15 28. Mark each shift fork, shift rail, and position in the holding fixture to make reassembly easier. Lift the shift rails from the support tool. Refer toshift Rails in this section for shift rail disassembly procedures. 29. Lift the countershaft off the bench stand. Separate the input shaft from the mainshaft. Lift the mainshaft from the stand. Refer to Mainshaft, Countershaft and Input Shaft in this section for mainshaft, countershaft and input shaft disassembly and assembly procedures. 30. Remove the rear cover from the holding fixture. Refer to Transmission Rear Case in this section for rear case disassembly and assembly procedures. Assembly 1. Place the input shaft and synchronizer ring assembly over the tapered roller bearing on the input end of the mainshaft. 2. Place the mainshaft and input shaft on the Gear Pack Holding Fixture T87T-7025-HH or equivalent. Place the countershaft on the fixture and mesh the gears of the two shafts.

Page 8 of 15 3. Place the three shift rails and fork assemblies into the Shift Rod Support Tool T87T-7025-JH or equivalent in the position from which they were removed during disassembly. 4. Position the three shift rail assemblies together with the shift rod support tool and interlock so that the shift forks engage in the correct mainshaft sliding sleeves. 5. Place the shift interlock on the three gearshift rails and engage it in the interlock grooves in the 5th-reverse (upper) rail. 6. If equipped, slide the speedometer worm gear onto the mainshaft until it seats against the stop on the mainshaft. NOTE: Make sure speedometer gear is installed with metal spacer toward bearing. 7. Secure the rear case into the bench mounted holding fixture T57L-500-B or equivalent. 8. Position Nylon Lifting Sling D87L-1000-A or equivalent around the shift rails, the holding fixture and the mainshaft and countershaft. Position the gear pack into the rear case and push the shafts and rails forward until the bearings seat in their outer races in the housing and the gearshift rails slide into their retaining holes in the housing.

Page 9 of 15 9. Rotate the gear pack and rear case upwards 90 degrees so it is in a vertical position with the input shaft pointing upwards. 10. If equipped, slide the output flange onto the output end of the mainshaft until it seats against its stop. Screw the hex nut onto the shaft until it is finger-tight. 11. Remove the shift rod support tool from the ends of the shift rails. 12. Remove the strap and remove the gear pack holding fixture from the mainshaft and countershaft.

Page 10 of 15 13. Attach the three cap screws that secure the shift interlock to the rear transmission housing. Tighten them to 10 Nm (7 ft-lbs). Be sure that the interlock moves freely after tightening the screws. 14. Engage the teeth of the reverse idler gear with the reverse gear on the mainshaft. Slide the reverse idler shaft downward through the bearings and into the rear case. Align the lower of the two threaded holes in the shaft with the bore in the rear case. Place a sealing ring on the capscrew and attach the screw through the bore in the housing into the shaft. Tighten the screw finger-tight. 15. Insert the central shift rail and finger assembly into its bore in the rear case. 16. If the magnet was removed during disassembly, insert it in the recess in the housing.

Page 11 of 15 NOTE: The tapered roller bearings preload should be adjusted if either the front or rear cases, countershaft, mainshaft, input shaft, or a bearing has been replaced. If the tapered roller bearings on the mainshaft, input shaft, or countershaft have to be adjusted, do not apply the sealant at this time. 17. If the tapered roller bearings on the mainshaft, input shaft or countershaft do not have to be adjusted, thinly coat the sealing surface of the rear case with Gasket Maker E2AZ-19562- B (ESE-M4G234-A2) or equivalent. NOTE: Do not wait longer than ten minutes to tighten all 17 bolts, due to the rapid curing time of the sealant. CAUTION: Do not use silicon Sealing Compound or equivalent. 18. If removed, push the three shift rail detents back into their holes in the front case. CAUTION: Make sure that the shift rail detents do not obstruct entry of the shift rails. 19. Carefully place the front case over the shafts and gearshift rails until it rests on its mating surface on the rear case. It may be necessary to push the central shift rail inward to clear the inner surfaces of the front case. CAUTION: Be careful that the input shaft does not damage the front seal. Also be careful that the shim pack oil baffle is not bent when the case is positioned over the input shaft. 20. Drive in the two dowels that align the rear case and the front case. Next, insert two hex screws and tighten them finger-tight.

Page 12 of 15 21. Screw two additional hex screws into the rear case bores near the shafts finger-tight. NOTE: If it is not necessary to adjust the mainshaft/input shaft preload, install all of the hex screws that attach the two cases and tighten to 22 Nm (16 ft-lb). CAUTION: Adjustment of tapered roller bearing preload is necessary if either the front or rear cases, countershaft, mainshaft or input shaft has been replaced, or if a tapered roller bearing on either shaft has been replaced. Refer to adjustments in this section for tapered roller bearing preload adjustment procedure before continuing assembly procedures. 22. Fit sealing ring to the remaining reverse idler shaft retaining capscrews. Install the screw into the bore in the front case and tighten both capscrews to 22 Nm (16 ft-lbs). With a screwdriver, push caps into the capscrews until they are flush with the surface of the screw head. NOTE: The rear case capscrew was installed finger-tight in step fourteen. CAUTION: Use hand pressure for screwdriver only, do not hammer the caps into position. 23. Rotate the transmission so the input shaft is pointing down. 24. On 4x2 transmissions (except F-Super Duty), remove the hex nut that secures the output flange to the mainshaft, then remove the flange from the shaft. Position the output shaft seal on Output Seal Replacer T87T-7025-BH or equivalent and position the seal and tool in the opening in the rear case. Apply a little liquid soap around the circumference to minimize friction. Using a soft hammer, gently tap the output seal replacer until it seats in the opening. 25. On 4x4 and F-Super Duty transmissions, use Output Seal Replacer T87T-7025-LH or equivalent and Seal Installer Tube T77J-7025-B or equivalent to install the output shaft oil seal. Gently tap on tube with a soft hammer until tool seats against its stop.

Page 13 of 15 26. On 4x2 transmissions (except F-Super Duty), reinstall the output flange on the output shaft. Install Companion Flange Holder T78P-4851-A. Install a new hex nut onto the mainshaft using locknut socket Tool T87T-7025-AH. Tighten the nut to 250 Nm (184 ft-lbs). CAUTION: Do not reuse the output flange retaining nut after any servicing of the transmission. Always replace it with a new one. 27. Position a 4.76mm (3/16-inch) punch on the locking shoulder of the retaining nut and bend the shoulder into the groove of the output shaft. 28. If required, install new gaskets and PTO covers over the openings in the front case using the original attaching screws which have self-sealing threads and tighten to 38 Nm (28 ftlbs). 29. Position the 5th-reverse gear interlock plate into its installed position as shown in the illustration. Place the gasket over the shift tower mating surface in the front case. NOTE: Make sure that the stop plate moves freely and that the gasket does not interfere with it. The interlock plate must be in a position which is lower than the gasket so that the plate may move freely.

Page 14 of 15 NOTE: Make sure that the interlock plate and spring do not drop into the front case. 30. Check the interlock plate compression spring against Spring Specifications at the end of this section to be sure that its unloaded length is satisfactory. 31. Place the spring above the nose in the interlock plate and move both parts into their installed positions. CAUTION: The procedure must be followed exactly to ensure that the interlock function between fifth gear and reverse gear operates properly. 32. Install the shift tower assembly. The nose on the gearshift finger must point toward the interlock plate. Install spring washers and tighten screws to 22 Nm (16 ft-lbs). 33. Check the functioning of the interlock. The shift lever cannot be shifted between fifth and reverse if the interlock was properly installed. CAUTION: Do not force the lever to shift into reverse. Damage to the interlock components could occur. 34. A compression spring is installed into each of the three detent bolts. The positions are shown in the illustration. Before installing the springs, check that their unloaded length is 44.1mm (1.736 inch). 35. Install a new sealing cap in each bore in the front case where the detents, bolts and springs were installed. Use a suitable drift or punch to drive each cap in until it seats 1mm (3/64 inch) below the surface of the housing. NOTE: Deeper installation will cause high shift efforts.

Page 15 of 15 36. If removed install the back-up lamp switch with a new sealing ring into its mounting boss on the side of the front case near the transmission nameplate. Tighten the switch to 20 Nm (15 ft-lbs).